Apparatus for flexographic printing process with wet on wet capability

ABSTRACT

The present disclosure is related to an apparatus for a flexographic printing process with wet on wet capability based on controlled polymer or polymer segment precipitation that leads to gel formation of ink compounds by controlling the solubility parameter of the ink system. Insoluble segments in the ink form a reversible gel that is broken to a liquid by heat and/or shear forces during the application process, allowing application of a liquid ink. After application, the ink reverts to its gel state with such strength as to allow overprinting in the wet on wet flexographic printing process. The disclosure is also related to a flexographic printing apparatus comprising a feeding system for providing a flexographic ink, wherein the ink in a liquid state has a viscosity ranging from about 100 cps to about 4,000 cps, and the ink in a gel state has a measurable hardness.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.13/165,623, filed Jun. 21, 2011, which is a continuation ofPCT/BR2009/000416, filed Dec. 22, 2009, which claims priority ofInternational PCT Application No. PCT/BR2008/000399, filed Dec. 22,2008, the content of both incorporated herein by reference in theirentirety.

FIELD OF THE INVENTION

This invention concerns to a flexographic printing process with wet onwet capability that is made possible by controlled gel formation basedon precipitation of a polymer or segments thereof in ink formulations,causing formation of a gel with suitable mechanical strength to allowthe required color trapping for a wet on wet flexographic printingprocess. This controlled precipitation is accomplished by controllingthe Hansen Solubility Parameter of the ink system at all times. The weton wet printing process is possible with or without intermediate airdrying, with greatly reduction or no emission of VOLATILE ORGANICCOMPOUNDS (VOC), greatly reduced use of energy, and with a single finalcuring step by UV or EB radiation. The invention also concerns an inkand a printing apparatus for carrying out the process. The process isalso suitable for letterpress printing.

BACKGROUND OF THE INVENTION

Flexographic printing has become the major printing process to produceflexible packages for food and non food products, especially in Northand South Americas and share roughly an equal part of the production ofgravures in Europe.

In Asia and in the Middle East the share of flexographic participationis still increasing since its quality continues to grow and thecapability to print Asiatic characters is now easily obtained.

Flexographic printing has achieved many improvements since its inventionlike the anilox rolls that bring more consistency in the inking process,and the introduction of the closed inking chamber, that reduces exposureto volatile solvents present in the ink and maintains the ink viscositystable for longer periods. Photopolymers were certainly one of thebiggest contributions to quality, followed by direct laser engraving inthe last 10 years. All of those contributions has forced the developmentof better inks and one of the most important components of those betterinks is their color strength.

There is a close similarity between printing quality and screeningresolution, anilox screening and volume of ink, particularly ink colorstrength. To improve the printing quality it is mandatory to increasealso the screening that we are using. Gravure and offset use 150 to 200lines per inch while the traditional flexography screening requestsranges between 100 and 140 lines per inch. The ability to avoid thesmallest dots in the plate to penetrate into anilox cells defines therelation between the screening of plates and the anilox screening sincefor the anilox this relation is about 6-8 times bigger than for theplates.

In order to print 200 lines per inch it is necessary an anilox with 1200to 1600 lines per inch, and as the anilox lines increase, the volume ofinks to be transported decreases fast, even using the new YAG laserengraving technology to bring higher volume to the anilox rolls, demandsof stronger inks to achieve the specified color densities for printingstill existing.

Table 1 below shows a standard anilox charter available for flexographicprinting nowadays.

TABLE 1 Anilox Screening versus Volume L/inch 150 205 250 305 355 410460 510 560 610 660 710 Min.¹ 9.0 7.0 5.5 4.5 3.8 3.2 2.9 2.7 2.4 2.21.7 1.6 Max.¹ 18.0 14.0 11.5 9.5 7.2 6.2 5.3 5.0 4.2 3.8 3.2 4.4 L/inch760 815 865 915 965 1020 1120 1220 1320 1400 1500 Min.¹ 1.5 1.5 1.4 1.41.4 1.3 1.2 1.2 1.2 1.0 1.0 Max.¹ 4.2 4.0 4.0 3.5 3.0 2.9 2.6 2.4 2.01.8 1.6 ¹Volume in BCM (billions of cubic micron per square inch)

The reduced volume of high anilox screening as shown above is one of thegreat limitations on traditional flexographic inks which contain 50% to70% of solvent in their composition reducing the possibility to increasethe pigment load in the ink and consequently the ink color strength.

To increase the complexity in order to achieve high color densitiesdemanded by the flexographic printing process it is not easy totranspose to the substrate all the ink present in the anilox since theink layer remains partially on the anilox roll and in the printing platesurfaces.

The high Volatile Organic Compounds (VOC) and the low density colorstrength are two main residual problems for flexographic printing,constituting the next challenge to be achieved: obtaining a betterquality ink and also developing a friendly environmental ink for theflexographic printing process.

U.S. Pat. No. 5,690,028, relates to a viscous radiation curable ink andthe decrease of the ink viscosity by heating it before the application.After applied, the ink layer cools down and the viscosity increasesagain to an amount enough to support the overprint of other color andgive a satisfactory color trapping. The main disadvantage verified onU.S. Pat. No. 5,690,028 is the difficulty to control the temperature ofthe ink and ensure that no significant variation occurs during theprinting process.

Other inventions tried to solve these problems in many different ways.In the U.S. Pat. No. 6,772,683, incorporated herein by reference, it issuggested to use low viscosity flexographic printing inks which have aviscosity controlling diluents to implement wet trapping of thesequentially applied ink layers by controlling time between the inklayer. However, the time required for the solvent evaporation is toolong.

U.S. Pat. No. 7,479,511 discloses a water based formulation usingbasically the same concepts of above mentioned U.S. Pat. No. 6,772,683in terms of how the ink layers can be overprinted, but also focuses onthe mobility of the reactive materials inside the final applied film,since lack of molecules mobility can lead to a low degree of conversionafter the cure process.

In addition, U.S. Pat. No. 7,479,511 also uses some water retention toguarantee the necessary mobility of the system in order to achieve thedesirable conversion degree. A correct amount of water is proposed as acompromise between minimum retention level and ability to withstand theoverprint process in flexographic printing.

PCT/US2005/012603 proposes a layered material having two or more layersthat can be curable by exposure to highly accelerated particles such asan electron beam. The layered material comprises a substrate, an inkformulation on at least a portion of the substrate. The ink formulationcomprises ink and a monomer curable by free radical or cationicpolymerization, and a lacquer comprising at least one monomer curable byfree radical or cationic polymerization.

The above discussed solutions require high investments to addultraviolet radiation (UV) or Electron Bean radiation (EB) installationsand even the cost of the inks are high in comparison to the traditionalsolvent inks. Those patents are based exactly in the same principle thatoccurs in the traditional solvent based system, since the intermediatedrying in the Central Drum Flexographic machines is not strong enough toresult in a completely dried ink layer.

Evidence that interstation drying of the flexographic printing processis not capable to assure complete drying of the ink, is given by acontinuous research for low tack resins for flexographic solvent inks,since the tack of the non completely dried ink creates problems to theprinting process, including color trapping and plate dust among others.

On the other side, the increased viscosity of the above discussed inksresults in the difficulty to reach a total conversion of all reactivematerials due to a low mobility created by the high viscosity, problemthat U.S. Pat. No. 7,479,511 tries to solve by leaving some amount ofwater up to the moment that the ink passes through the curing system (EBor UV) and by implementing a complex balance of the presence of water.

OBJECTS OF THE INVENTION

It is an object of this invention to provide a flexographic printingsystem and process with the overprint color process without solvent orwith a reduced amount of solvents, and at the same time providing inksthat have higher color strength and exhibit a good adhesion to majorsubstrates currently on the market.

Another object of this invention is a ink compositions that show thecapability to print in a wet on wet basis and to be cured at the end ofthe process only, i.e., when leaving the printing machine, by means ofultraviolet radiation (UV) or Electron Bean radiation (EB).

SUMMARY OF THE INVENTION

The object of this patent may be achieved by providing a flexographicprinting process involving gelation of the ink once applied to thesubstrate, said process being characterized by two important principles:the gelation or gel formation of the ink on the substrate and the use ofHansen Solubility Parameter to reach this gelation. This process is anoverprint color process that uses reduced VOLATILE ORGANIC COMPOUNDS(VOC) content that means a reduced amount of solvents, and at the sametime providing inks that have higher color strength and exhibit a goodadhesion to major substrates currently on the market.

In this process the changes in Hansen Solubility Parameter of the ink isachieved by the printing machine which is able to change the inkformulation and it's solubility using devices that control thephysicochemical ink characteristics, for example, in each ink layerbefore the application on the substrate and using only a final cure ofthe multilayer ink film by appropriate radiation (UV/EB). The devicesresponsible for controlling the physicochemical ink characteristics areknown of the state of the art and are usually found on flexographicprinters.

This invention also discloses a flexographic printing ink curable byUV/EB radiation which is a gel composed by a polymer and a combinationof liquids mainly consisting of radiation curable monomers and/oroligomers, diluents, colorants, additives and/or photoinitiators, andoptionally small amounts of non-reactive solvent. These compounds arecombined to create a system with the ability to form a gel during whatis customarily called the drying phase of the flexographic printingprocess. The controlled gel results from formation of a polymer chainnetwork, or polymer segment precipitation forming such a network,because of a lack of solvency in the liquid media. This process can beunderstood and therefore controlled, if at all possible, by the HansenSolubility Parameter as will be better discussed in the following.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 and FIG. 2 show a schematic representation to explain thetheoretical concept of changing and/or controlling the Hansen SolubilityParameter which sustains the present invention.

FIG. 3 shows a diagrammatic representation of a traditional flexographicPrinting Press;

FIG. 4 shows the flexographic Printing Press containing an EBcapability.

FIG. 5 shows the flexographic Printing Press containing an UVcapability.

FIG. 6 shows a microphotograph of a gel network formed by polyvinylAlcohol in water, with characteristic frames of polymer and a hugevolume of free space filled by liquid. FIG. 6 also shows the nanoscalestructure of a hydrogel's polymer network. The bar (lower right)represents 0.2 micrometer. L. Pakstis and Pochan; From Science News,Volume 161, No. 21, May 25, 2002, p. 323.

FIG. 7 schematically shows a Hansen Solubility Parameter Chart with thepositions of some desired monomers such as HDDA (1,6 HexanediolDiacrylate), TMPTA (Trimethylolpropane Triacrylate), TRPGDA(Tripropylene Glycol Diacrylate), and some of the most desirablesolvents such as the Glycol Ethers and Esters in general.

FIG. 8 represent an evaluation chart of VOLATILE ORGANIC COMPOUNDScontent during a printing run, and demonstrate the low level of VOLATILEORGANIC COMPOUNDS of the present invention, with the peak of VOLATILEORGANIC COMPOUNDS with less than 25 mgC/Nm³ (milligrams of Carbon perNormal cubic meter of air).

FIGS. 9 to 11 show different possibility of construction for theflexographic inking system able to handle gellified flexographic inks.

FIG. 12 shows a graphic of the gel hardness vs. gellant concentrationfor Polyvinyl Butyral (Butvar B76).

DETAILED DESCRIPTION OF THE INVENTION

In this description the following definitions will be used.

Viscosity is defined as the resistance of a fluid (liquid or gas) to achange in shape, or movement of neighboring portions relative to oneanother. Viscosity denotes opposition to flow. The reciprocal of theviscosity is fluidity, a measure of the ease of flow. Molasses, forexample, has a greater viscosity than water. Because part of a fluidthat is forced to move carries along to some extent adjacent parts,viscosity may be thought of as internal friction between the molecules;such friction opposes the development of velocity differences within afluid.

For many fluids the tangential, or shearing, stress that causes flow isdirectly proportional to the rate of shear strain, or rate ofdeformation, that result. In other words, the shear stress divided bythe rate of shear strain is constant for a given fluid at a fixedtemperature. This constant is called the dynamic, or absolute, viscosityand often simply the viscosity. (Encyclopedia Britannica) L. Z. Rogovinain Polymer Science Series C ISSN 1811-2382 (Print) 1555-614X (Online)DOI 10.1134/S1811238208010050 of 2008 proposes the following definitionto gel: “a gel is a solid composed of at least two components, one ofwhich (polymer) forms a three-dimensional network by virtue of covalentor noncovalent bonding (chemical and physical gels, respectively) in themedium of the other component (liquid), wherein the minimum amount ofthe liquid is sufficient for ensuring the elastic properties of the gel,although it may exceed tens to hundreds of times the amount of thepolymer. It is noted that, at a high network density or highpolymer-chain rigidity, the formation of fragile gels is possible. Ageneral feature of physical gels is the existence of the yield point”.

The same author also published on 1974 the following gel definition: “Agel is taken to be a polymer-solvent system in which the polymer,present at very low concentration, forms a quite stablethree-dimensional network in the solvent. Consideration is given to theproperties of gels in which the network is formed both by chemical andby physical bonds; attention is paid mainly to the second group of gels,in which variation in temperature produces a reversible transitionbetween gel and solution.” (L Z Rogovina et al 1974 Russ. Chem. Rev. 43503-523 DOI: 10.1070/RC1974v043n06ABEH001821).

The definition of Hansen solubility parameter as found in Wikipedia issimple but complete and precise.

Hansen Solubility Parameters, also named reverse solvency principle,were developed by Charles Hansen as a way of predicting if one materialwill dissolve in another and form a solution. They are based on the ideathat like dissolves like where one molecule is defined as being ‘like’another if it bonds to itself in a similar way.

Specifically, each molecule is given three Hansen parameters, eachgenerally measured in Mpa^(0.5):

-   -   δ_(d) The energy from dispersion bonds between molecules    -   δ_(p) The energy from polar bonds between molecules    -   δ_(h) The energy from hydrogen bonds between molecules

These three parameters can be treated as co-ordinates for a point inthree dimensions also known as the Hansen space. The nearer twomolecules are in this three dimensional space, the more likely they areto dissolve into each other. To determine if the parameters of twomolecules (usually a solvent and a polymer) are within range a valuecalled interaction radius (R₀) is given to the substance beingdissolved. This value determines the radius of the sphere in Hansenspace and its center is the three Hansen parameters. To calculate thedistance (Ra) between Hansen parameters in Hansen space the followingformula is used:(Ra)²=4(δ_(d2)−δ_(d1))²+(δ_(p2)−δ_(p1))²+(δ_(h2)−δ_(h1))²Combining this with the interaction radius gives the relative energydifference (RED) of the system:RED=Ra/R ₀

-   -   RED<1 the molecules are alike and will dissolve    -   RED=1 the system will partially dissolve RED>1 the system will        not dissolve

Summarizing the differences between those concepts, it is defined thatgel is a two phases system, composed by a solid network phase swollen bya liquid phase, instead a single phase of viscous homogeneous liquid. Infact, the establishment of the two phases by a second order transitionin the moment of gelation instead of a first order transition ofviscosity increasing is the major difference between the two phenomena.

Also a very important differences between gel and viscous liquidsresides on the fact that gel has no defined viscosity, since the gel hasno yield value up to the gel is destroyed and after that, without anychange in the formulation or in the temperature, but only in the appliedshear rate, gel show infinity viscosities, making impossible define aprecisely viscosity.

Wet trapping, or wet on wet ink printing, is a printing process in whicha first layer of ink deposited at a first inking station is not dry whena second layer of ink is superposed to the first layer at a secondinking station. Wet trapping is disclosed, e.g., in US 2003/0154871.

The first object of the invention provides a flexographic printingprocess which comprises the following steps:

-   -   a) Printing on a substrate a first layer of a radiation curable        ink suitable for wet on wet flexographic printing, said ink        comprising a combination of one or more non-reactive polymers        and optionally one or more non reactive solvents with at least        one reactive monomer and/or oligomer, pigments and additives,        whereby said polymer(s) are only partially soluble in said        monomer(s) and/or oligomer(s) or soluble after adding non        reactive solvents;    -   b) Bringing said printed first ink layer to a gel state, said        gel ink layer having a strength sufficient to withstand        subsequent printing steps;    -   c) Subsequently printing a second ink layer in a liquid state        over at least part of said previously gelled first ink layer,        said second ink layer changing into a gel layer upon printing;    -   d) Printing all sequential ink layers following the steps a)        to c) up to the point that all colors are applied on to the        substrate.    -   e) Curing simultaneously all the ink layers at the end of the        process using EB or UV radiation.

The desirable multiple layer overprinting required by this process isachieved by gel formation in each applied layer prior to application ofthe next layer with a final cure of the multilayer ink film byappropriate radiation (UV/EB). This mechanism is completely differentfrom the usual liquid viscosity increase present in all traditionalflexographic printing process and also employed in the previous art asdescribed in the patents above discussed.

Control of the gelling process can be best accomplished when the HansenSolubility Parameter of the medium is adjusted and/or changed so thatthe ink system becomes incapable of keeping the selected polymer, orsegments in the selected polymer, in a truly dissolved condition, thatis to say in solution. The ultimate result of this controlledinsolubility is polymer, or polymer segment, precipitation leading toformation of a swollen gel having contact points where polymer orpolymer segments meet. These polymer entities “join” together, not beingable to reside in the liquid where there is controlled insolubility.Stated in another way, the insoluble polymer entities seek each other,having similar/identical Hansen solubility parameters. They are not ableto reside in the liquid where the Hansen solubility parameters are toodifferent to allow solution as discussed in more detail in thefollowing.

The controlled gelling process creates a network of polymer chains thatresembles a solid-like system with respect to the forces that are activein the overprinting flexographic process. This relative strength is thereason for a successful wet on wet overprinting process. Each gelledlayer has the capacity of supporting itself and also to acceptsubsequent color layers without problems.

The precipitation or gel forming process may be controlled to occur, forexample, even if only a small part of the nonreactive solvent, when itis present, evaporates. Some polymers are made of separate blocks orsegments that are covalently bonded into one large molecule. In theevent that some of the polymer segments are insoluble by the monomersand oligomers that form at least part of the “solvent” medium of theink, while other polymer segments are indeed soluble by them, then it ispossible that a suitably gelled system, physically bound together by theinsoluble segments, can works without the use of nonreactive solvents orwith limited amounts of these. In such cases shear forces alone canconvert such reversible gels to liquids, with the gel rapidly reformingon the printed surface. An example of such a system is a polyester (oroil modified polyester) that also has blocks or segments of a polyamide.The different solubility characteristics of the polyester portionscompared with the polyamide portions allow gelling based onnon-solubility of the polyamide parts to each other in a liquid whichdoes indeed dissolve the polyester. In principle the reverse gel couldalso be generated by dissolving the polyamide segments and precipitatingthe polyester segments, but the liquids required for this are notfavorable environmentally and in practice as those required fordissolving polyester. Polymers with dual nature of this kind can alsoallow extremely low amounts of nonreactive solvents being required toproduce the desired gels.

Gelled films produced by the methods of this invention can beoverprinted much faster and more readily than those formed by theviscosity increase mechanism of the prior art; they are provided withexcellent trapping properties than are in general much better than thewet trapping properties obtainable through offset printing.

During the precipitation, the polymers create a network in the mediumthat results in a solid-like system with respect to the forces that willact in the overprinting flexographic process, and creates thepossibility of carrying out said overprinting process—i.e. the capacityto support and accept the other colors layers onto pre-printed ones. Inthe flexographic printing process, the gel is instantaneously formedwhen applied in a very thin layer with very high color strength inks.The applied layer in flexographic printing varies between 0.3 to 2.5microns, on average; under the influence of a surface energy from thesubstrate and of the previously applied ink layers (if any), the gelformed in the printing process can be considered as an instantaneous gelformation.

The gel strength is preferably expressed and identified by giving thegel hardness in an appropriated scale as Shore 00, measured by ASTMD2240-05 Standard Test Method for Rubber Property on the gel as formed,before gel curing. Under the laboratory conditions, to measure thedesirable gel hardness, preparation of a sample of ink big enough (a fewhundred grams) is needed also due to the size of the Durometer.

This flexographic printing involving gelation of the ink once applied tothe substrate with a completely different approach to solve thecompromise of wet trapping and cure degree. The solution of the problemresides on the totally different system state, i.e. a gel rather than aconcentrated solution. With respect to those know in the art there areprovided by the present invention two important principles anddifferences: the gelation or gel formation of the ink on the substrateand the use of Hansen Solubility Parameter to reach this gelation.

Additionally, all agitation generated during the printing phase ceasesafter ink deposition onto the substrate, given a substantial help to thegellation of the applied ink layer.

The gel state is defined as a solid-like by the main researchers of thematter, but a solid that has a huge degree of mobility of the liquidsinside of the system and also a state that can be reversed to a liquidstate by certain amount of heat, in the same order that the one that isgenerated in the moment of the cure by the exothermic reaction.

Motion caused by shear forces, for example, can also convert gels toliquids, especially when the polymer forming the gel has blocks orsegments that are not soluble in the liquid phase, whereas some otherparts of the polymer are truly soluble in the liquid phase. The shearforces can be sufficient to pull the gelled segments apart, allowingthem to again reform a gel when the external shear forces are no longerpresent. This situation can also be used to produce inks of quality andperformance similar to those containing smaller amounts of nonreactivevolatile solvent. In any case control of the Hansen SolubilityParameters in the inks is required as discussed in the following.

The invention refers to a flexographic process with wet on wetcapability (wet trapping) based on gel formation or gel temporarydissolution of flexographic printing inks by controlling the HansenSolubility Parameter of the ink system. The mechanism to obtaindesirable wet on wet color trapping is based on gel formation in theapplied ink using a controlled physicochemical mechanism of polymerprecipitation. This can be done by controlling the Hansen SolubilityParameter, for example, by heating or by evaporation of a non-reactiveand volatile solvent, leaving behind a liquid that does not dissolve agiven polymer or segments thereof.

This flexographic printing process with wet on wet capability based oncontrolled precipitation leading to a gelation of ink formulations bychanging the Hansen Solubility Parameter of the ink system applying heatin the ink used, with or without intermediate air drying and final cureby radiation means. The process can use radiation curable inks which arecured only after all colors are applied onto a substrate. A flexographicink has a viscosity of less than 4000 cps, preferably less than 2500 cpsand most preferably less than 1000 cps when it is applied to the finalsubstrate.

This invention analyses what can be defined as reverse solvency,controlling or changing the Hansen Solubility Parameter of the medium insuch way as to get some modified degree of solvency or solvation of thechosen polymer to produce a gel, or solid-like, layer of ink havingenough strength and rigidity to support a flexographic overprint processor a letterpress printing process.

The great advantage of this principle is the ability to produce thisphenomenon with a very low level of solvent, because of the operationalbasis of Hansen Solubility Parameters. The selection of polymer andliquids that will compose the final formulation can be done in such away as to have Hansen Solubility Parameters of the incompatible reactiveliquid in the gel right in the solubility border of the polymer, or justmarginally solvate of given segments of the polymer. Very small changesin the amount of an appropriate solvent or modification in thesolubility parameter of the reactive liquid with the right HansenSolubility Parameters can adjust the state from liquid to gel or viceversa.

The present invention, based on gel formation of the ink during theprinting process, namely between two adjacent inking stations, allowsthe successful practice of the overprinting process. As can be seen inFIG. 6, the present invention takes advantage of both the mobility ofthe low viscosity liquid throughout the huge free space within thepolymer gel network and of the gel destruction during the curing. Thisgel destruction is caused by the heat generated by the exothermicchemical reaction during curing. It is well known that physical gels arevery sensitive to heat. The film once more becomes liquid orliquid-like, and can flow together to form a strong cured print. Thesolubility regions shown in FIGS. 1, 2, and 7 increase with highertemperature, and liquids with Hansen Solubility Parameters just outsidethe solubility boundary at room temperature become good solvents atelevated temperature. In the present invention this effect aids in thedesired breaking of the gel at higher temperatures. This concept is atthe basis of the ink which is the second embodiment of the invention,where a gelled ink is initially prepared to be just outside thesolubility boundary at room temperature.

The high mobility of the reactive components during the cure process inthe gel, and after the gel is broken as the temperature increases in thecuring phase, assures the highest degree of chemical conversion withoutany additional control or apparatus.

This flexographic printing process use a flexographic printing machinethat comprises means for heating or subjecting to shear forces a gelledink as above discussed, i.e. a gel ink that is suitable to be changed byagitation or heat application from a gel state into a fluid ink withless than 4000 and preferably less than 2500 cps in order to beapplicable by the ink system present in the flexographic printingmachine.

It is therefore a further object of the present invention a flexographicprinting machine that comprises means for heating and/or means forstirring or applying a shear force to an ink before applying said ink tothe final substrate.

A flexographic printing machine according to the invention comprisesmeans for heating or subjecting to shear forces a gelled ink as abovediscussed, i.e. a gel ink that is suitable to be changed by agitation orheat application from a gel state into a fluid ink with less than 4000and preferably less than 2500 cps in order to be applicable by the inksystem present in the flexographic printing machine.

As shown in the figures, said machine comprises ink transfer meansincluding anilox rolls and printing plates, further comprising cleaningmeans to remove excess ink applied over the anilox rolls in such way asto leave the ink only inside of the anilox roll cells, like a bladeapplied in gravure or conventional flexographic system, with or withoutenclosed chamber.

FIGS. 9 to 12 shows a possible designs for the new flexographic printingmachine, although different designs are not excluded, those designscover a reasonable range of possibilities and shows a easily way toadapt especially the flexographic printing machine in a such way toturns the use of gelled ink easier than the traditional solvent flexoinks like IroFlex™ series from Toyo Inks and FlexiRange™ fromFlintGroup.

More specifically, FIG. 9 shows a Flexographic printing machine with acentral drum and two different feeding systems under references 1 and 2.In reference 1 there is provided an automatic or manual feeding system(1.2) feeding the Ink Tray (1.1) that supply the ink directly to theanilox roll (1.3), cleaned by a Doctor Blade (1.6) and then inking theplate on plate cylinder (1.4) and from the plate, ink is applied to thesubstrate. The contention can (1.5) is located bellow all inking systemto avoid contamination of other color in case of spilling.

Additionally, FIG. 9 under reference 2 shows a Flexographic printingmachine with automatic or manual feeding system (2.2) feeding the InkTray (2.1) that supplies the ink to the metering roll (2.3) to reducethe amount of ink transferred again to inking roll (2.4) and from theinking roll to anilox roll (2.5), cleaned by Doctor Blade (2.8) and theninking the plate on plate cylinder (2.6) and from the plate, ink isapplied to the substrate (not shown). The contention can (2.7) islocated below all inking system to avoid contamination of other color incase of spilling.

FIG. 10 shows two other possible constructions of the inking system tohandle the gelled ink. Under reference 3 is shown a feeding system (3.2)feeding the Ink Tray (3.1) that supplies the ink directly to anilox roll(3.4) after the amount of applied ink to the anilox is controlled by themetering roll (3.3), then the excess of ink is cleaned by a Doctor Blade(3.7) and then the residual ink in the anilox roll is applied to theplate cylinder (3.5) and from the plate, ink is applied to thesubstrate. A contention can (3.6) is located below the whole inkingsystem to contain spilled ink and avoid contamination of other color incase of spilling.

The reference 4, on FIG. 10, presents a different inking system in theabsence of conventional ink tray, replaced by a system similar to thatused in the field of solventless laminators, where the gelled inkreservoir (4.3) supplied automatically or manually by feeding system(4.2) is formed by a low speed metering roll (4.1) and medium speedmetering roll (4.4) that apply a sufficient amount of ink to completelycover the anilox roll (4.6) cleaned from this excess of ink by the blade(4.5) to be applied as a very thin layer over the printing plateattached to the plate cylinder (4.7) and then finally transferred to thesubstrate. As in the other examples, the contention can (4.8) must beapplied to prevent color contamination in case of ink spilling.

As shown in the FIGS. 3, 4, 5, 9, 10 and 11, said machine comprises inktransfer means including anilox rolls and printing plates, furthercomprising cleaning means to remove excess ink applied over the aniloxrolls in such way as to leave the ink only inside of the anilox rollcells, like a blade applied in gravure or conventional flexographicsystem, with or without enclosed chamber.

After printing, the temperature decreases again to desirable range andthe agitation ceases leading the ink to the gel state again. The printedink layers became a gel state upon the substrate surface and all thoselayers shows enough rigidity to assure the wet trapping of the incomingnext colors, up to the appliance of all color and subsequently exposedto radiation energy to initiate the curing/polymerization of curablecomponents of the ink. This embodiment has the advantage of providing aflexographic printing ink that is free from organic solvents, i.e. thatis VOLATILE ORGANIC COMPOUNDS free. Such a characteristic is of theutmost importance for the economy of the printing process and apparatus.

Current flexographic printing technology uses 6 to 12 sequential colorsto achieve the final result, but it is very rare that more than 4 or 5colors are applied one over the other, because trapping problems becomemore significant in thicker layers of ink, even with traditional solventbased inks.

FIG. 3 shows a traditional Flexographic Printing Press, where theCentral Drum (CD), the anilox cylinders (1), the plate cylinders (2),the driers (3), and the encapsulated doctor blades (4), are represented.

As mentioned before the present invention can be performed without anymachinery modification, except by the addition of EB or UV curing unitat the end of the process, if such is not already present, when thesubstrate leaves the final drying tunnel (5), as shown in FIG. 4 for EBcapability and in FIG. 5 for UV capability.

According to FIG. 4, the substrate is transferred from the unwinder (U)to the central drum (CD) and then to the final drying tunnel (5) andthen to the Electron Beam device (EB) and to the rewinder (R). A similarpath is found in the situation shown in FIG. 5. Here the substrate,after passing through the final dryer tunnel (5) reaches the chill rolls(6) and Ultraviolet light devices (UV), as lamps and reflectors, andthen to the rewinder (R).

The main problem to use those inks especially in flexographic process isthe management of the ink in the gel state, since the heating of the inkdemand time and the pumping system of traditional flexographic machinesare very sensitive to the presence of high viscosity inks inside of thesystem.

Also the extension of the tubes that conduces the ink through the inkingsystem is a source of more problems and difficulties to the printers. Inorder to solve those problems and since the inks can show a VOLATILEORGANIC COMPOUNDS free formulations, the solution can be related to theuse a different flexographic inking system, without the doctor bladessystem.

The invention also provides a gelled flexographic printing ink curableby UV/EB radiation which comprises a polymer and a combination ofliquids mainly consisting of radiation curable monomers and/oroligomers, additives, photoinitiators, and optionally small amounts ofnon-reactive solvent and where the said polymer act as a gellant.

All components used in this ink has the Hansen Solubility Parameters,and this flexographic printing ink is normally a gel having the requiredphysical characteristics and is brought to a liquid state during theprinting process, usually by means of mechanical or thermal action,becoming a liquid with viscosity suitable to be used in flexographicprinting (e.g. of less than 4000 and most preferably less than 2500 cps)and that return to a gel state after having been applied to the finalsupport.

For those ink formulations that contains solvent to adjust thesolubility parameter, the time to evaporate enough solvent to form thegel state is sufficient also to allow the right gel hardness tomeasures, but as gel is formed even with partial removal of the solvent,the best measures is taken after solvent removal, e.g. after a constantweight of the sample is achieved to ensure a complete solvent removal,and preferably not before 15 minutes after the temperature of theprepared formula reaches the temperature of the room.

In the case of solvent free ink formulations, 30 minutes is usuallyrequired to establish the gel in samples of a few hundreds grams with aconstant and stable measurement.

First, the invention provides an ink within the Hansen SolubilityParameters with a non reactive solvent which is at least in partevaporated to provide the required gel and is normally a gel having therequired physical characteristics and is brought to a liquid stateduring the printing process, usually by means of mechanical or thermalaction in the cases of non application of non reactive solvent.

If the ink still using solvent in the formulation, the inventionprovides at least two great improvements over traditional solventflexographic inks:

-   -   very strong inks with a viscosity below 2.500 cps are easily        achieved due to a characteristic of selected monomers and        oligomers which are able to print in a wet on wet basis and        exhibit a high load pigment capacity;    -   the inks obtained can show a reduced VOLATILE ORGANIC COMPOUNDS,        even below 15% of total formula, in comparison with formulation        inks from prior art having high solids solvents that use about        50% of VOLATILE ORGANIC COMPOUNDS in their composition.

The combination of those two characteristics—very strong color inks andlow VOLATILE ORGANIC COMPOUNDS—gives an ink the capability to meet theEuropean and American VOLATILE ORGANIC COMPOUNDS and pollutionregulations, without any pre or final treatment in the air or residues.These measures reduce the cost of final products, improve the inkquality and contribute to the environmental preservation.

If a solvent are added into the ink composition, the main criteria tochoose the solvent can be summarized as follows:

-   -   a) The selected solvent must show stability in the medium (e.g.        avoid Alcohols and Glycols that could undergo        transesterification in a short period of time, generating toxic        acrylates).    -   b) A nonreactive solvent useful in this invention should be        chosen from those that are the most human friendly as possible,        with low skin and respiratory irritation, and also being        compatible with the final destination of the ink (Flexible food        packaging, for instance).    -   c) In order to minimize the amount of nonreactive solvent added,        preferred choices will have Hansen Solubility Parameters as far        as possible from the Hansen Solubility Parameters of the final        formulated mixture. The Hansen Solubility Parameters of mixtures        are calculated from weight (or volume) averaging of the Hansen        Solubility Parameters of the individual components. The effect        of a given component on this average is greater at the same        concentration when its Hansen Solubility Parameters are further        from the final average. This provides the potential for greatly        reduced levels of nonreactive solvent.    -   d) The Hansen Solubility Parameters and concentration of any        nonreactive solvent that may be present must lead to a final        position on the Hansen Solubility charts, such as those shown in        FIGS. 1, 2, and 7, that is just within the region defined by the        polymer radius of solubility. Its evaporation will then lead to        the desired gel formation, since the Hansen Solubility        Parameters of the liquid remaining are then moved to just        outside the boundary defining the solubility of the polymer.        This leads to the gel formation as above disclosed.    -   e) In Hansen Solubility Parameter diagrams such as those shown        in FIGS. 1, 2, and 7, the line connecting the averaged Hansen        Solubility Parameters of the liquids in the formulated ink and        the Hansen Solubility Parameters of any chosen solvent in the        formulation should preferably pass through the polymer center of        solubility since this is the most sensitive point for efficient        gel destruction resulting in a low viscosity flexographic        applicable ink with less than 4000 cps and preferably less than        2500 cps and mostly preferably less than 1000 cps of the        formulation.    -   f) The boiling point of any chosen nonreactive solvent that may        be in the formulation is preferably lower than the boiling point        of any of the monomers present in order to assure its        evaporation without any noticeable loss of monomers.

With respect to the selection of solvents for the practice of thisinvention, preferred solvents are those with medium to low relativeevaporation rates, preferably between 5 and 100 on the relativeevaporation rate scale with the evaporation rate of n-Butyl Acetatebeing set equal to 100. The solvent should have very low toxicity andsuitable Hansen Solubility Parameters in relation to the majority of theUV/EB monomers and oligomers to control the gel process as describedabove.

Following the established criteria for selection of the rightnonreactive solvents for practice of the present invention, preferredsolvents include, but are not limited to: Propylene Glycol MonomethylEther, Dipropylene Glycol Monomethyl Ether, Propylene Glycol MonomethylEther Acetate, n-Propyl Propionate, n-Butyl Propionate, n-PentylPropionate, Propylene Glycol Diacetate, Diethyl Carbonate, and DimethylCarbonate. The use of nonreactive solvents having medium to low relativeevaporation rates such as propylene glycol monomethyl ether ordipropylene glycol monomethyl ether also improve the ink stability inthe machine allowing up to 72 hours of printing without any interferenceof operators to adjust the viscosity. This means the standard ofimpression also remains constant during this time which, in turn, meansa very desirable, stable flexographic printing process.

The preferred non-reactive solvent used in the present system may or maynot dissolve the polymer directly. This is because the monomers,oligomers, and nonreactive solvents used may have Hansen SolubilityParameters outside of solubility region/volume of the polymer as shownin FIGS. 1, 2, and 7. This is possible, since it is their mixtures thatmust have the appropriate Hansen Solubility Parameters to allow controlof the printing process as disclosed here.

It is mandatory, however, that the medium, after the partial or totalevaporation of any nonreactive solvent in the formulation, is anon-solvent for the polymer, or given segments of the polymer, in orderto control formation of a the gel.

If there is no solvent in the present ink, i.e. the flexographic ink isa VOLATILE ORGANIC COMPOUNDS free ink; the radiation curable phasechange ink comprises a non-curable gellant consisting of or including ablock polymer partially insoluble in the reactive medium at roomtemperatures of about 15° C. to about 35° C.

The VOLATILE ORGANIC COMPOUNDS free ink of this patent should containthe following components: a curable gellant consisting of or including ablock polymer partially insoluble in the medium reactive at roomtemperatures of about 15° C. to about 35° C., includes additionalcurable monomers and oligomers as well as curable or non-reactivepolymers and gel-promoting additives, selected in such way as to preventthe formation of a single phase ink at room temperature in standardconditions, additives and the ink may optionally contain a small amountof a solvent.

Summarizing, the method provides for preparation of a solid, gelledradiation curable ink film using a formulation having a partly solublepolymer, where the partly soluble polymer has blocks or segments thatare not soluble in the medium liquid of the ink formed by radiationcurable oligomers and monomers. These insoluble segments or blocks jointo form the links in the gel in such a way that this gel state is brokenby agitation, heat or a combination of both, thus allowing the printingof a liquid ink film. The printed liquid ink reverts to the gelled stateafter printing and removal of agitation, and can thus be in a conditionsimilar to the final films in a) above. Such films can withstand thephysical effects found during printing, and also provide the colortrapping required for wet-on-wet multilayer printing processes,particularly flexographic and letterpress printing.

Known organic gellants that are suitable to turn a VOLATILE ORGANICCOMPOUNDS free radiation curable printing ink into a gel at roomtemperature said gel being easily destroyable by means of temperature,agitation, or combination of both, creates a possibility to produce asystem and the right ink formulations to overcome the limitations thatstill obligate the formulas to contain a non reactive diluents to thewet on wet printing process in flexography and at the same time avoidthe use of high viscosity inks in letterpress that demands more pressureand exhibits more difficulties to print.

Preferably, the gellant forms a solid-like gel state in the ink mediumat temperatures below the temperature at which the ink will be printedand handled by the inking system and this solid-like gel is based in thephysical gel formation that exhibit two phases, one constituted by anetwork formed by the non completely solved polymer by non-covalentbonding interactions such as hydrogen bonding, Van der Waalsinteractions, aromatic non-bonding interactions, ionic or coordinationbonding, London dispersion forces, and the like, and the second phaseconstituted by the medium liquid inside the cavities of the polymernetwork.

With the use of physical forces such as temperature or mechanicalagitation, the gel of the present invention can be reversed into aliquid with just one phase, close to a sol system and showing adesirable viscosity to the selected printing process.

The flexographic printing ink based on phase change as per the presentinvention, include a photoinitiator when the intended cure process isdesired to be an Ultra Violet light means, both by free radical orcationic cure.

Photoinitiator useful for the present invention includes but not limitedto 2,4,6-trimethylbenzoyldiphenylphosphine oxide;bis(2,4,6-trimethylbenzoyl)-phenyl-phosphine oxide;2-methyl-1-(4-methylthio)phenyl-2-(4-morphorlinyl)-1-propanone; 2-benzyl2-dimethylamino 1-(4-morpholinophenyl)butanone-1;2-dimethylamino-2-(4-methylbenzyl)-1-(4-morpholin-4-ylphenyl)-butanone;diphenyl-(2,4,6-trimethylbenzoyl)phosphine oxide;2,4,6-trimethylbenzoylphenylphosphinic acid ethyl ester; oligo(2-hydroxy-2-methyl-1-(4-(1-methylvinyl)phenyl)propanone);2-hydroxy-2-methyl-1-phenyl-1-propanone; benzyl-dimethylketal; andmixtures thereof.

The use of amine synergists, such as ethyl-4-dimethylaminobenzoate and2-ethylhexyl-4-dimethylaminobenzoate is highly recommended due to itsinfluence on overall cure speed.

The photoinitiator range from about 0.5 to about 25%, preferably fromabout 1 to about 10%, by weight of the ink. The above remarks onphotoinitiators apply also to the first embodiment, i.e. to the reducedsolvent ink above discussed.

The desirable viscosity of less than about 4000 cps in the applicationcondition (temperature and agitation), preferably less than 2500 cps andmostly preferably less than about 1000 cps, and a hardness of at least 4shore 00 under ASTM D2240-05 Standard Test Method for Rubber Property.

The temperature variation to ensure the transition between both states,gel to liquid is below 80° C., and preferably below 40° C., i.e. if thedesired final temperature is a room temperature of 28° C., theapplication temperature must be below 108° C. and preferably below 68°C.

The easy way to assure the temperature reduction is the refrigeration ofthe flexographic central drum and the counter-pressure cylinder inletterpress. As the substrate is surrounding those cylinders, thetemperature of the applied ink decrease faster, leading to gellation.

The VOLATILE ORGANIC COMPOUNDS free ink does not contain solvents butonly monomers, oligomers, polymer (which act as a gellant) andadditives; forming a radiation curable medium that are comprised by oneor more of Polyester acrylates, Epoxy acrylates, Acrylic acrylates, andPolyurethane acrylates, Trimethylolpropane Triacrylate (TMPTA),Tripropyleneglycol Diacrylate (TRPGDA), 1,6-Hexanediol Diacrylate(HDDA), n-Vinyl Pyrrolidone (NVP), n-Methyl Pyrrolidone (NMP), and thelike.

The choice of suitable polymers to practice this invention requirescare. The selection is really restricted by the need to find a polymerhaving a boundary of solubility which can be used to advantage. Thefinal liquid ink formulation must have Hansen Solubility Parameters nearthis border, with control over how the Hansen Solubility Parameters maychange during the printing process. Among the most adaptable polymersare the Polyvinyl Butyrals and some polymers or copolymers of methylmethacrylate or other acrylic copolymers.

If there is no solvent in the present ink, i.e. the flexographic ink isa VOLATILE ORGANIC COMPOUNDS free ink; the radiation curable phasechange ink comprises a curable gellant consisting of or including ablock polymer partially insoluble in the reactive medium at roomtemperatures of about 15° C. to about 35° C.

The use of the composite gellant, e.g. a partially soluble polymer,enables the ink to form a gel state having a hardness of at least 4shore 00 by the ASTM D2240-05 Standard Test Method for Rubber Propertyat temperatures of about 15° C. to about 35° C. To obtain the fluidityrequired for use in the flexographic printing process, the ink is heatedor stirred (i.e. shear forces are applied to the ink), or both, so thatthe gel state is destroyed and the ink has enough fluidity (i.e. aviscosity of less than 4000 cps and preferably less than 2500 cps andmostly preferably below 1000 cps) to be handled by the printing systemin a manner to be applied in the final substrate.

The gel formation process in the case of the present invention isstrictly limited to physical bonds, using, as above mentioned, a verylow level of polymer, with a range between 0.1% to a 10% in a medium ofmore than 50% of liquid of the final formulation, where the majority iscomposed by a reactive non-volatile monomer or monomers and oligomers,preferably low viscosity ones that necessarily have appropriate HansenSolubility Parameters.

One very important property of gels that relates to the two mainconcepts of the present patent (Gel formation and Hansen SolubilityParameters) is the influence of solvency of the medium on the gelstrength obtained by the degree of network formation that gives more orless rigid gel structure (hardness) and stickiness (tack). In a verypoor polymer solubility medium, the polymer molecules are spread outwithin the medium as a network, rather than being clumped together, asbriefly explained above.

This creates a very strong gel structure created by a polymer networkwith a liquid phase within it.

The selection of the polymer and the formulation of the ink compositionare done to avoid phase separation (liquid-solid) when the gel system isformed. A careful balance of the Hansen Solubility Parameters isrequired.

The polymer network formed in the gel must retain the relatively largeamount of liquid inside the network, which means that some attractionlevel, sometimes called solvation, must be maintained between extendedpolymer chains and the liquid. It can be seen, therefore, that theformation of the right kind of gel is connected to the other importantconcept of the present invention, controlling the Hansen SolubilityParameters to provide the correct degree of gel strength at the righttime.

It was found that ink gels suitable for the present invention andcapable of withstanding subsequent printing and provide wet trapping arethose that have hardness of at least 4 shore 00 by the ASTM D2240-05Standard Test Method for Rubber Property, Durometer Hardness. Seewww.astm.org and ASTM Volume 09.01 Rubber, Natural and Synthetic—GeneralTest Methods; Carbon Black. Preferred hardness is of at least 7 Shore 00and most preferably at least 10 Shore 00. The upper limit is selectedaccording to the final use and is preferably (but not necessarily) of 50Shore 00 and more preferably of 25 Shore 00. The hardness of the gel ofthe prepared sample is measured 15 minutes after the gelled ink hasreached a constant weight, i.e. after complete solvent evaporation, atroom temperature (i.e. 15 to 35° C.). In the case of solvent free inkformulations, gel hardness of the prepared sample is measured 30 minutesafter gel forming, at room temperature (i.e. 15 to 35° C.).

Preferred polymers include, but are not limited to, Butvar® B76, Butvar®B79, Butvar® B90, Butvar® B98 produced by Solutia, Inc, Elvacite® 2013,Elvacite® 2016, Elvacite® 2046, produced by Lucite International, Inc.Other suitable polymers are dendritic polymers having different polymersegments; an example of this type of polymers is Boltorn® U3000 producedby Perstorp.

The amount of polymers in the final ink composition, before it isgelified is within the range of 0.5% to 15% (w/w) of the total inkcomposition, preferably, between 1% to 5% by weight of the total inkformulation.

The Hansen Solubility Parameters of many more polymers and monomers andoligomers can be defined in order to formulate further ink compositionsaccording to the present patent.

The polymer precipitation will act in the radiation curable mediumsimilar to the action of a magneto applied to a medium of iron balls,diffusing its surface energy by the whole system and leading to agelation of the system. The precipitation or gelation may be adjusted tooccur even if only a small part of the solvent is evaporated and canshow the results much faster and stronger than the viscosity increase.

The radiation curable phase change ink compositions also comprises of acurable epoxy-polyamide composite gellant in an amount from about 1% toabout 50% by weight of the ink, more preferably from about 5% to about25% by weight of the ink, and most preferably from about 7% to about 15%by weight of the ink, although the value can also be outside of thisrange.

According to the present invention, the gelation is also obtained fromnon reactive polymers, advantageously but not necessarily even with avery small quantity of solvent, especially depending on the Polymerselected. Useful percentages of those solvents may vary from 1% up to15% (w/w) of the total ink composition.

For example, where the organic gellant is cationically curable (e.g.,wherein the curable functional groups include epoxy, vinyl ether, allyl,styrene and other vinyl benzene derivatives, or oxetane groups),additional cationically curable monomers or oligomers may be included inthe ink vehicle.

Cationically curable monomers may include, for example, cycloaliphaticepoxide, and preferably one or more polyfunctional cycloaliphaticepoxides. The epoxy groups may be internal or terminal epoxy groups suchas those described in WO 02/06371, incorporated herein by reference.Multifunctional vinyl ethers can also be used.

The additional curable monomers and oligomers as well as curable ornon-reactive polymers and gel-promoting additives, selected in such wayas to prevent the formation of a single phase ink at room temperature instandard conditions.

The criteria to select the monomers can be summarized by the followingbasic points referring to Hansen Solubility Parameter positions in FIGS.1, 2 and 7:

-   -   a) The Hansen Solubility Parameter average for the final        monomer/oligomer combination (one or more monomers) must not        directly dissolve the chosen polymer, that is the point in the        figures for this mixture will be outside the region of complete        solubility for the polymer;    -   b) The Hansen Solubility Parameter average for the final        monomer/oligomer combination is preferred to be close to the        polymer solubility border in order to minimize the amount of        solvent to be used and to take additional advantage of the gel        breakage with increased temperature. That is the point        representing this mixture should be very close to the boundary        of solubility in FIGS. 1, 2 and 7, but just outside of this        region;    -   c) The final monomer/oligomer combination must be selected in        order to produce a low viscosity ink (less than 4000 cps and        preferably less 2500 cps and mostly preferably below 1000 cps);    -   d) The selection of monomer is tailored to the final        application, for instance, only some of the radiation curable        monomers are allowed to be used to produce Flexible Food        Packaging, which means that the formulation for Flexible Food        Packaging must follow the country or regional regulations.    -   e) The monomer's boiling point must preferably be higher than        that of any nonreactive solvent that may be present in order to        keep the monomers within the ink layer after the nonreactive        solvent has evaporated.

The chosen monomers or oligomers on a Hansen Solubility Parameter chartof the kind shown in FIGS. 1, 2, and 7. The experimental determinationsare certainly the most reliable and will lead to the most probablevalues of the monomers in the solubility space, but minor revision ofthese Hansen Solubility Parameter values can be expected.

Use of the experimental method allowed determination of the HansenSolubility Parameters for a number of UV/EB monomers that canbeneficially be used in formulations according to this invention. Thesevalues can be advantageously used on plots of the kind given in FIGS. 1,2, and 7, for example, or even with more refined computer processing ifsuch is available.

Preferred radiation curable materials are selected, without limiting,from the following group: Trimethylolpropane triacrylate (TMPTA),1,6-Hexanediol diacrylate (HDDA), Tripropylene Glycol Diacrylate(TRPGDA), Ethoxylated (3) Trimethylolpropane Triacrylate (TMP3EOTA),Ethoxylated (6) Trimethylolpropane Triacrylate (TMP6EOTA), Ethoxylated(9) Trimethylolpropane Triacrylate (TMP9EOTA), Propoxylated (6)Trimethylolpropane Triacrylate (TMP6POTA), Propoxylated (3) GlycerylTriacrylate (G3POTA), Di Trimethylolpropane Triacrylate (DTMPTA),Dipropylene Glycol Diacrylate DPGDA, Ethoxylated (5) PentaerythritolTetraacrylate (PPTTA), Propoxylated (2) Neopentyl Glycol Diacrylate(NPG2PODA), Ethoxylated (2) 1,6 Hexanediol Diacrylate (HD2EODA).

The amount of monomers in the final ink composition, before it isgelified is within the range of 0% to 80% (w/w) of the total inkcomposition, preferably, between 30% to 50% by weight of the total inkformulation.

The addition of monomers is useful since the combination of monomers,oligomers, and nonreactive solvents allows control over the HansenSolubility Parameters of the formula at all times, and gives a goodsolvency to selected polymers, with resulting low viscosity and highsolids. Since monomers will not be evaporated with the solvent due totheir higher boiling point and since they will not be present in thecured ink as such, having been reacted into the cross-linked ink duringthe final cure, they are included in the solids.

In case oligomers are used instead of monomers, the non reactive polymershould be incompatible with the chosen oligomers and have a very lowviscosity to allow the formulation of the ink with a desirableviscosity, preferably between 1000 cps to 2500 cps. The preferredpercentage of oligomers is within the range of 45% to 60% by weight ofthe total formulation.

The recommended oligomers to be mixed or not with monomers includes, butare not limited to, low viscosity Epoxy Acrilate, Amine Acrilate,Polyester Acrylate, Epoxidized Soybean Oil Acrylate. The oligomers arepresent in an amount of 0 to 80% (w/w) of the total ink composition; thetotal amount of oligomers and monomers preferably is within the range of10% to 35% (w/w) of the total ink composition.

In this patent, ink additives can be diluents, colorants, stabilizeradditives, leveling additives, dispersing additives and/or synergistadditives.

The reactive diluents material is preferably added to the ink in amountsof from, for example, 0 to about 80% by weight, preferably about 1 toabout 80% by weight, more preferably about 35 to about 70% by weight, ofthe ink.

Useful colorants for the system includes all main organic pigments asper the following non-limiting list: Yellow 3, Yellow 12, Yellow 13,Yellow 17, Yellow 74, Yellow 83, Yellow 114, Yellow 121, Yellow 139,Yellow 176, Orange 5, Orange 13, Orange 34, Red 2, Red 53.1, Red 48.2,Red 112, Red 170, Red 268, Red 57.1, Red 148, Red 184, Red 122, Blue15.0, Blue 15.3, Blue 15.4, Violet 19, Violet 23, Green 7, Green 36 andBlack 7. The use of inorganic pigments like Titanium Dioxide ismandatory for white inks and some iron pigments are desirable forcertain applications.

Additives play an important role in the formula, especially in order toachieve a high pigment loading with low viscosity and to improve somefinal properties like wettability of plastics substrates, scratchresistance, foam control, etc.

Main additives recommended include, but are not limited to, Byk 019™,Byk 023™, Byk 361™, Byk 3510™, Disperbyk 163™, Dysperbyk 168™(manufactured by Byk Chemie), Foamex N™, Airex 900™, Tegorad 2100™,Tegorad 2500™, Tego Dispers 651™, Tego Dispers 685™, Tego Dispers 710™(manufactured by Tego Chemie), Solsperse 5000™, Solsperse 22000™,Solsperse 32000™, Solsperse 39000™ (manufactured by Noveon), DC 57™,DC190™, DC 200/500™ (manufactured by Dow Corning), Genorad 21™(manufactured by Rahn), Omnistab 510™ (manufactured IGM Resins).

The amount of colorants and additives is within the usual range in thisart. However, the type and amount of colorant will affect the gelhardness.

Based on the concept described in the present invention many formulavariations of the kind described here may be implemented by formulatorsskilled in the art. There are a large number of choices regardingnonreactive solvents, solvent-soluble resins, monomers and oligomersthat would allow compliance with the claims of this invention. Also, theHansen Solubility Parameters for many other monomers and oligomers arenot currently known. Such data would help develop ink formulationswithin the scope of this invention without requiring numerous trials.

This invention also allows formulation of inks with very strong color,which in turn allows satisfactory application of thinner ink films. Suchinks require polymer along with the monomers and/or oligomers in orderto incorporate the pigments in a well dispersed and stabilized manner togive transparent, glossy and pure color inks. The amount of ink appliedis such as to obtain a thin ink layer: the thinner the ink layer, themore rigid this layer will be since it is closer to the solid state, aswell as to a substantially more rigid base to the other ink layers thatwill be printed over it.

The inks formulated according to this invention can be applied intraditional Flexographic Machines, also with a conventional aniloxcylinder and doctor blade, but it is desirable to improve the aniloxcylinder to near 480 lines/cm and less than 2.5 cm³/m² (1200 lines perinch and 1.6 BCM) in terms of four process colors and 250 lines/cm—5.5cm³/m² (600 lines per inch and 3.5 BCM) for white and black colors usinga thick blade or a blade like the Superhoned® Gold by Allison SystemsCorp.

According to an aspect of the invention, to achieve wet trapping in alltrial conditions, especially when the maximum trapping of colors isbelow 300% (maximum 3×100% colors overprinted), a little quantity of airinsufflations is used in order to assure the complete removal of allsolvents of the dried film. This reduces the possibility of residualodor or solvent to be retained, especially dealing with food packagepurposes.

Cold air is usually suitable for this purpose. This will significantlyreduce use of energy and contribute to reduction of CO₂ emissions sincegas burning driers can be avoided. This is made possible by the use ofthe gel technique of the invention and the destruction of the gel by theheat of reaction generated during the cure process itself, such that noexternal heat is required.

Moreover, if the ink layer is thin, the evaporation of any residualnonreactive solvent will occurs much easier, which means lowered heatdemands, and also faster drying. This can lead to avoid the use of anyexternal heat source particularly since the physical gel is broken byheat generated by the polymerization reaction during the cure step ofthe invention process; this heat of reaction is sufficient to evaporateany nonreactive solvent present.

As previously mentioned, VOLATILE ORGANIC COMPOUNDS (VOC) emissions inthe invention process are dramatically low and lower than known printingprocesses because the invention results in extremely high solid inkswith very low levels of nonreactive solvents that require less attentionby printers and also show very good performance compared to any otherUV/EB or solvent/water inks.

In the following Table 2, comparative results for the same operatingconditions are given.

TABLE 2 Comparison of solvent emission based in a UV/EB formulationSolvent Solvent content Strength Application Production Ink usedemission Type of Flexo ink (%) (%) (g/m²) (m²) (kg) (kg) UV/EB-Invention10% 250% 2 1,000,000 m² 2000 200 Standard Solvent ink 60% 100% 51,000,000 m² 5000 3000

The Table 2 above demonstrates a comparison of solvent emission based ina UV/EB formulation designed following the present patent basis againstthe usual solvent base ink. The final result in terms of VOLATILEORGANIC COMPOUNDS emission is 15 times less emission in the UV/EBinvention inks than in a pure solvent base ink.

FIG. 1 schematically demonstrates the concept of the present inventionbased on the Hansen Solubility Parameter. FIG. 1 uses δp, the PolarHansen Solubility Parameter versus δh, the Hydrogen Bonding HansenSolubility Parameter. All the good solvents for the polymer define thesolubility region (solubility sphere since there are three HansenSolubility Parameters). This is schematically given by the circle Ahaving a center C and radius R. All liquids, whether reactive or not,such as solvent (S) within the circle will dissolve the polymer whilethe monomer (M) will not since its location is outside of the solubilitysphere.

FIG. 2 uses the same type of plot as FIG. 1 to demonstrate the change inthe Hansen Solubility Parameters of the ink after evaporation of anonreactive solvent S. As it can be observed by comparing these figures,the average Hansen Solubility Parameters of the liquids (F) in the inkmove from just within the circle boundary in the as-supplied state, tojust outside of this boundary after removal of any nonreactive solvent.The desired gel formation is then effected.

As previously mentioned in given cases it may be possible to use apolymer with special segments that are not soluble in the liquid of theink as supplied, with gel formation from the start. This gel can bereadily degraded by shear forces in the printing process to provide aliquid that can be transferred within the printing equipment asdescribed above. The gel is then reestablished between the steps wherethe different colors are applied in the wet on wet printing process.There are no shear forces of significance after the ink is applied, sothe gel will be formed rapidly again.

As described by many authors skilled in the art, such as Van Kevelen andHoftyzer (Van Krevelen, D. W.; Hoftyzer, P. J. Properties of Polymers.Correlation with Chemical Structure; Elsevier: NY, 1972), Hansen(Hansen, Charles (2000). Hansen Solubility Parameters: A user'shandbook. Boca Raton, Fla.: CRC Press) and Hoy (K. L. Hoy, The Hoytables of solubility parameters, Union Carbide Corp., 1985), acombination of two compounds in a suitable amount can result in atheoretical new single solvent. In the present situation, the formulatedsolvent F (50% monomer M and 50% solvent S) results exactly in themiddle point of the line that joins both S and M. Since the “newsolvent” is inside the solubility area, it will be able to dissolve asolvent resin A. On the other hand, monomer M is a high molecular andhigh boiling point and after printing in the flexographic process,solvent S, that is much more volatile than monomer M, begins toevaporate. As a consequence, the point that represents in the graphicthe formulated solvent F moves towards the “remaining solvent”. FIG. 2shows the new position of formulated solvent F after 50% of solvent Sevaporation and no evaporation of monomer M.

The process continues up to the point where there is no solvent S leftand the formulated solvent F is coincidental with monomer M because itwill be the unique present compound. But much before that situation, theformulated solvent F will be out of the solubility area of thesolvent-based resin A, and then the solvent-based resin A willprecipitate in the medium of monomer M, giving the ink a gel consistencythat is enough to support the overprint process. Experiments show an inkwith “good” to “excellent” color trapping.

The formation of a suitable gel network in the ink after its applicationand prior to application of subsequent inks of different colors andradiation curing of the whole composite layered print comprises thefollowing steps:

-   -   a) formulating a radiation curable ink system suitable for wet        on wet flexographic printing by combining non-reactive polymers        and, if desired, small amounts of nonreactive solvents with        reactive monomers and oligomers;    -   b) enabling the wet on wet printing capability by a new        mechanism known as Hansen Solubility Parameter control by means        of evaporation of any non-reactive solvent, leading to        precipitation of the non-reactive polymer to form a gel with        sufficient strength to support the sequential color overprint        process, or alternatively adjusting the Hansen Solubility        Parameters with reactive monomers and oligomers only such that a        polymer with both soluble and insoluble segments in the mix of        reactive monomers and oligomers without any nonreactive solvent,        can attain suitable gel strength by precipitation of the        non-soluble segments, recognizing that the shear forces during        application of the ink will reversibly render it to be a liquid,        thus allowing its ready application and cure;    -   c) applying all sequential colors to complete the flexographic        printing process, said colors are prepared based on the above        mentioned new mechanism;    -   d) curing simultaneously all the ink layers collectively at the        end of the process using EB or UV radiation.

This new mechanism is extremely helpful and can reduce significantly, orperhaps even eliminate, the volatile, nonreactive solvent in theformulation.

The similarity of operational care between this family of inks and thecustomary solvent based inks also ensures the easy adaptation of theprinters to the new technology.

To simplify the calculations and the presentation, the Hansen dispersionparameter for the reactive monomers has not been considered in thesecases, since it is reasonably similar to the Hansen dispersion parameterof the other components in the system all of these being linear instructure and not having halogens or other larger atoms of the kind thatincrease the dispersion parameter.

Illustrative examples of some formulations produced according to thepresent invention are given below. These examples, however, can not beconstrued as limiting. Alternatives or variations encompassed within thescope of the claims are clearly to be considered as being within thescope of this invention.

Table 3 below resumes the Hansen solubility parameters of the some usualraw materials in the market, including the ones chosen for the followingformulation examples.

TABLE 3 Hansen solubility parameters of the some usual raw materials inthe market PRODUCT δp (J/cm³)^(1/2) δh (J/cm³)^(1/2) MONOMERS TMPTA 15.09.0 HDDA 11.2 11.8 TRPGDA 13.5 10.0 SOLVENTS Diethyl Carbonate 3.1 6.1Dimethyl Carbonate 3.9 9.7 Dowanol DPM¹ 4.1 10.2 Dowanol PM² 7.2 13.6n-Butyl Propionate 1.6 3.3 Proglyde DMM³ 2.1 3.8 PIGMENT CARBON BLACK6.0 5.5 POLYMERS R₀ Butvar B76 4.3 12.7 10.4 Parlon P10 6.2 5.3 10.4Ethocel STD 20 6.9 5.9 9.9 Lutonal IC/1203 2.5 4.6 12.4 Piccoumarone450L 5.4 5.6 9.4 Elvacite 2016 8.0 5.0 8.2 ¹Dipropylene Glicol MethylEther ²Propylene Glicol Methyl Ether ³Dipropylene Glicol Dimethyl Ether

Example 1 Ink with Small Amount of Solvent

Formula A is for an EB curable ink formulated according to the presentinvention for a non-food application that contains only 5% solvent and0.5% of Polymer (Polyvinyl Butyral—Butvar® B76): Formula A is showed onTable 4 below.

TABLE 4 ink with small amount of solvent FORMULA A Product Trade NameSupplier Yellow Magenta Cyan Black Additive Omnistab 510 IGM Resins 0.50.5 0.5 0.5 Additive Tego Glide 432 Tego Chemie 1.0 1.0 1.0 1.0 AdditiveTego Dispers 685 Tego Chemie 4.0 2.5 — — Additive Disperbyk 168 Altana3.0 5.5 6.5 5.0 Monomer TMPTA Cytec 51.0 51.0 51.0 48.5 Monomer HDDACytec 5.0 5.0 5.0 4.5 Epoxidized Soy CN111 Sartomer 5.5 6.0 6.0 6.0 BeanOil Acrylate Additive Solsperse 22000 Noveon 2.0 — — — AdditiveSolsperse 5000 Noveon — — 1.5 2.0 Yellow Pigment Irgalite Yellow LCTCIBA 22.5 — — — Magenta Pigment Permanent Rubine L4B 01 Clariant — 23.0— — Cyan Pigment Heliogen LBL 7081D BASF — — 23.0 — Black PigmentSpecial Black 250 Degussa — — — 27.0 Polymer Butvar B76 Solutia 0.5 0.50.5 0.5 Solvent Dowanol PM Dow 5.0 5.0 5.0 5.0 Viscosity (cps) 1500 17501350 2100 Color Density Anilox: 480 l/cm-1.85 cm³/m² 1.12 1.35 1.89 1.66

The production was carried out in a Comexi FW 1508 at a production speedof 350 m/min using only cold air in the interstation drying devices, andcured at 20 kGy in an EZCure-I DF™ produced by ESI (Energy SciencesInc.—Wilmington, Mass.).

The printed material was tested according to the scotch test method inadhesion and the results are given in the Table 5 below:

TABLE 5 Results from printed materials Printed Treatment Scotch MaterialLevel¹ Test² 1-Clear polypropylene 40 passed 2-Pearlized polypropylene40 passed 3-Clear polyethylene 38 passed 4-White polyethylene 38 passed¹Corona treatment ²Scotch ® 880

The present formulation shows the following trapping values, where theAchieved values, obtained through the invention, are compared to minimumvalues obtained according to known offset method.

Achieved Web Offset (min) Red: 75% 65% Green: 67% 75% Blue: 50% 70%

It is clear that gel strength achieved in the above formulation was notsufficient to ensure a minimum desirable trapping value for all colors,even if some colors achieve a little more than the minimum, it shows theinconsistency and potential problems that can occur during the printingruns.

In order to evaluate the formulation above, all variations on the HansenSolubility Parameter before and after a solvent loss of 5% of theformulation was calculated in the following Table 6 and the followingformula A was developed:

TABLE 6 Hansen Solubility Parameter FORMULA A - GENERAL PURPOSE MONOMERS(NOT FDA APPROVED) INITIAL FORMULA (A1) FINAL FORMULA (A2)* Compound A1δh (J/cm³)^(1/2) δp (J/cm³)^(1/2) A2 δh ((J/cm³)^(1/2) δp (J/cm³)^(1/2)TMPTA 83.6%  7.524 12.54 91%  8.19 13.65 HDDA 8.2% 0.9676 0.9184 9%1.062 1.008 TRPGDA   0% — — 0% — — Dowanol PM 8.2% 1.1152 0.5904 0% — —Total 100%  9.6068 14.0488 100%  9.252 14.658 *After all solventevaporation

After removing all other components of the formulation, and restrictingthe formula to the compounds which will form the solubilization medium,formula A gives the A1 liquid compound formula, where TMPTA represents83.6%, HDDA is equal to 8.25% and the 5% solvents in the total formulabecomes 8.2% of the liquid medium.

The Hansen Solubility Parameter variation of the initial Formula A1(before solvent evaporation) and Formula A2 (after solvent evaporation)is given below:

δh ((J/cm³)^(1/2) δp (J/cm³)^(1/2) Formula A1 9.6 14.0 Formula A2 9.314.7

Due to insufficient trapping in previous example, a behavior of the gelis well studied and hardness was defined as one of the properties thatbest represent the gel itself.

To provide the readings of the gel hardness, formulations with 5%, 4%,3%, 2% 1% of polyvinyl butyral (Butvar B76) by weight of the total nonvolatile was prepared for each basic colors (yellow, Magenta, cyan andBlack) and measured by means of a Shore 00 Durometer following the ASTMD2240-05 “Standard Test Method for Rubber Property” produced by WoltestCompany—Rua Francesco Mosto, 55—São Paulo—05220-005—SP—Brazil. This testmethod is based on the penetration of a specific type of indenter whenforced into the material under specified conditions; it is an empiricaltest.

A 150 g of total formula was produced for each color and concentrationand gellified in a can to leave the surface free and flat to apply theShore 00 Durometer reading head and obtain the correct measure.

This kind of Durometer is normally used to measure very soft polymericfoams, such as polyurethane foam used in pillows and mattress and theright reading is considered the reading obtained when the values havestabilized in a sequence of at least 3 consecutive readings. The test iscarried out on the gel after evaporation of enough amount of thesolvent, in order to change the Hansen solubility parameter and allowthe gellification of the ink for the cases where the solvent is presentin the formulation to adjust the Hansen solubility parameter or afterenough time in the cases of solvent free formulation.

Hardness is read after 15 minutes from the constant weight of thesample, which means the sample lose practically all solvent and reachthe highest hardness of the gelled ink.

It was found that this possibility of reading the gel hardness is a veryimportant physical difference between the invention inks and the knowninks that are based on viscosity increase upon solvent evaporation. Infact all attempts to read very high viscosity offset inks failed for alltypes of color because even when a hardness value was detected in afirst reading, the sequence of reading does not stabilize, decreasingeach time it is repeated to a point when the reading was no longerpossible to be done, because the Durometer sank in the viscous ink. Thisis due to the fact that a viscous ink does not establish a gelated basefor the readings.

The readings in the gel hardness in FIG. 12 explain quite well theresults achieved, where only the yellow ink had enough consistency tosupport the overprinting process. In fact it was found that gel hardnessis also depending on the type of pigment used; the same composition mayprovide a gel having sufficient hardness when yellow pigment is used anda gel not hard enough when black pigment is used, as discussed in thefollowing.

When the composition of Formula A was modified to include a greateramount of polymer, the trapping values improved dramatically as shown infollowing example 2.

The gel hardness vs. gellant concentration for Polyvinyl Butyral (ButvarB76) is reasonably linear for the selected percentage interval but whenhardness decreases below 5-6 shore 00 it is impossible to read it sincethe gel texture and consistence cannot support the measurement devicethat tends to sink in the ink. It was found by carrying out empiricaltests that below this lower limit value, i.e. 4 Shore 00, the gelstrength can no longer support the flexographic overprinting process.

The different behavior of the black inks can be explained as follows.Typical carbon black pigments have Hansen solubility parameters suchthat they readily adsorb common solvents and/or polymers. This caneasily affect the Hansen solubility parameters of the liquid phase inthe inks. The absorption of polymers, in particular, leads to a rapidincrease in viscosity, since the molecular weight of the carbon black,with say two polymer molecules adsorbed is approximately twice that ofthe individual polymer molecules. The effect on the viscosity ofdoubling the molecular weight is greater than that of the two individualpolymer molecules.

Data for the most conventional carbon blacks gives the following Hansensolubility parameters to the carbon black: δP: 6 (Mpa³)^(1/2) and δH 5.5(Mpa³)^(1/2), bringing the total Hansen solubility parameter to insideof the solubility performance of Polyvinyl Butyral (Butvar B76).

As the use of the black in all printing tests was programmed to be thelast printed color, the results were not affected by the insufficientgel hardness. To overcome the trapping problems of the first formulationand taking the information achieved from the hardness evaluation, a newformula was prepared with 2.5% Polyvinil Butyral in all colors asfollowing:

Example 2 Ink with Increased Amount of Polymer

In example 2, the amount of polymer was increased, that means aelevation in the polymer network density and in the amount of change inthe Hansen Solubility Parameter, in order to ensure a sufficientdistance between the liquid and gel state, avoiding ink gelation in theinking system. Table 7 shows Formula B.

TABLE 7 FORMULA B Product Trade Name Supplier Quantity Additive Omnistab510 IGM Resins 0.5 0.5 0.5 0.5 Additive Tego Glide 432 Tego Chemie 1.01.0 1.0 1.0 Additive Tego Dispers 685 Tego Chemie 4.0 2.5 — — AdditiveDisperbyk 168 Altana 3.0 5.5 6.5 5.0 Monomer TMPTA Cytec 46.5 46.5 46.544.0 Monomer HDDA Cytec 3.0 3.0 3.0 2.5 Epoxidized Soy CN111 Sartomer5.5 6.0 6.0 6.0 Bean Oil Acrylate Additive Solsperse 22000 Noveon 2.0 —— — Additive Solsperse 5000 Noveon — — 1.5 2.0 Yellow Pigment IrgaliteYellow LCT CIBA 22.5 — — — Magenta Pigment Permanent Rubine L4B 01Clariant — 23.0 — — Cyan Pigment Heliogen LBL 7081D BASF — — 23.0 —Black Pigment Special Black 250 Degussa — — — 27.0 Polymer Butvar B76Solutia 2.0 2.0 2.0 2.0 Solvent Dowanol PM Dow 10.0 10.0 10.0 10.0Viscosity (cps) 1250 1600 1250 1900 Density Anilox: 480 l/cm-1.85 cm³/m²0.97 1.32 1.79 1.47

The production was done in a Comexi FW 1508 at a production speed of 350m/min using only cold air in the interstation drying devices and curedat 20 kGy in an EZCure-I DF™ produced by ESI (Energy SciencesInc.—Wilmington, Mass.).

The printed material was tested in adhesion and the results are given inthe Table 8 below:

TABLE 8 Results from printed materials Printed Treatment Scotch MaterialLevel¹ Test² 1-Clear polypropylene 40 Passed 2-Pearlized polypropylene40 Passed 3-Clear polyethylene 38 Passed 4-White polyethylene 38 Passed¹Corona treatment ²Scotch ® 880

The main variation from the previous formula and this one (Formula B) isincreasing the amount of polymer (Polyvinyl Butyral—Butvar® B76) from0.5 to 2.0% and the amount of solvent from 5% to 10%.

It was clear when the new formulation was studied that the amount of thenonreactive solvent was not enough in the formula A to move the HansenSolubility Parameter of the final liquid mixture to a point sufficientlyinside the solubility region of the PVB to ensure the rightsolubilization. This was not so clear in the first formula due to theamount of PVB in the formula.

The level of solvent needed to adjust to a minimum level ofsolubilization was recalculated to 17% of the liquid compound (10% ofthe total Formula B) instead of 8.2% of the liquid formulation or 5% ofthe total formula of the Formula A. The Table 9 below gives the newsituation for the Hansen Solubility Parameters for the Formula B1(before solvent evaporation) and B2 (after solvent evaporation):

TABLE 9 Hansen Solubility Parameters for the Formulae B1 and B2 FORMULAB - GENERAL PURPOSE MONOMERS (NOT FDA APPROVED) INITIAL FORMULA (B1)FINAL FORMULA (B2)* Compound B1 δh ((J/cm³)^(1/2) δp (J/cm³)^(1/2) B2 δh((J/cm³)^(1/2) δp (J/cm³)^(1/2) TMPTA 78.0% 7.02 11.7 93.9%   8.45114.085 HDDA  5.0% 0.59 0.56 6.1%   0.7198 0.6832 TRPGDA   0% — — 0% — —Dowanol PM 17.0% 1.734 0.697 0% — — Total  100% 9.922 13.484 100% 9.1708 14.7682

The trapping results here are much improved as seen by the followingvalues:

Achieved Web Offset (min) Red: 89% 65% Green: 84% 75% Blue: 81% 70%

As the above data shows, the trapping values exceed by a good margin theminimum desirable trapping and also showed great stability during to theprinting run, even with a lot of stop and go operations. This is theworst scenario for testing trapping stability.

The Hansen Solubility Parameters in the Formula B1 show a good solvencyfor the polymer (PVB) ensuring a right solubilization with no noticeabletendency to gel formation. After the solvent evaporation, even with useonly of cold air and up to 350 m/min in a Comexi FW 1508, the trappingvalues were considered very acceptable and stable. The changes in theHansen Solubility parameters are given below:

δh ((J/cm³)^(1/2) δp (J/cm³)^(1/2) Formula B1 9.9 13.5 Formula B2 9.214.8

Example 3 Composition Approved for Food Packing

Using the same general formulation principle, but using only FDAapproved monomer for Food Packing, the previous formulations is changedby exchanging HDDA with TRPGDA (Tripropylene Glycol Diacrylate).

In both case, the use of HDDA and/or TRPGDA is directed to bring theTMPTA as close as possible to the solubility border of Butvar® B76 inorder to reduce as much as possible the Methoxy Propanol (Dowanol PM)level in the ink, since after its evaporation there is an adverse effectof VOLATILE ORGANIC COMPOUNDS in the atmosphere. Table 10 below showsformula C:

TABLE 10 gelled ink with small amount of solvent FORMULA C Product TradeName Supplier Quantity Additive Omnistab 510 IGM Resins 0.5 0.5 0.5 0.5Additive Tego Glide 432 Tego Chemie 1.0 1.0 1.0 1.0 Additive TegoDispers 685 Tego Chemie 4.0 2.5 — — Additive Disperbyk 168 Altana 3.05.5 6.5 5.0 Monomer TMPTA Cytec 37.5 37.5 37.5 36.5 Monomer TRPGDA Cytec12.0 12.0 12.0 11.0 Epoxidized Soy Bean Oil CN111 Sartomer 5.5 6.0 6.06.0 Acrylate Additive Solsperse 22000 Noveon 2.0 — — — AdditiveSolsperse 5000 Noveon — — 1.5 2.0 Yellow Pigment Irgalite Yellow LCTCIBA 22.5 — — — Magenta Pigment Permanent Rubine L4B Clariant — 23.0 — —01 Cyan Pigment Heliogen LBL 7081D BASF — — 23.0 — Black Pigment SpecialBlack 250 Degussa — — — 27.0 Polymer Butvar B76 Solutia 2.0 2.0 2.0 2.0Solvent Dowanol PM Dow 10.0 10.0 10.0 9.0 Viscosity (cps) 1370 1640 12802100 Density Anilox: 480 l/cm-1.85 cm³/m² 0.93 1.29 1.47 1.37

The production was carried in a Comexi FW 1508 with a production speedof 350 m/min using only cold air in the interstation drying devices andcured at 20 kGy in an EZCure-I DF™ produced by ESI (Energy SciencesInc.—Wilmington, Mass.).

The printed material was tested for adhesion with the results beinggiven in the Table 11 below:

TABLE 11 Results from printed material Printed Treatment Scotch MaterialLevel¹ Test² 1- Clear polypropylene 40 passed 2- Pearlized polypropylene40 passed 3- Clear polyethylene 38 passed 4- White polyethylene 38passed ¹Corona treatment ²Fita Scotch ® 880

Proceeding to the Hansen Solubility Parameter evaluation, the Table 12below shows the change in these before and after solvent evaporation:

TABLE 12 Changes in the Hansen Solubility Parameter FORMULA C - MONOMERSFDA APPROVED FOR FOOD PACKAGING INITIAL FORMULA (C1) FINAL FORMULA (C2)*Compound C1 δh ((J/cm3)^(1/2) δp (J/cm3)^(1/2) C2 δh ((J/cm3)^(1/2) δp(J/cm3)^(1/2) TMPTA 63.0% 5.67 9.45 75.9% 6.831 11.385 HDDA  0.0% 0 0 0.0% 0 0 TRPGDA 20.0% 2 2.7 24.1% 2.41 3.2535 Dowanol PM 17.0% 2.3121.224  0.0% 0 0 Total  100% 9.982 13.374  100% 9.241 14.6385 C1 are theHansen solubility parameters before solvent evaporation and C2 are theHansen solubility parameters after solvent evaporation.

Changes in the Hansen Solubility parameters are indicated below:

δh ((J/cm³)^(1/2) δp (J/cm³)^(1/2) Formula C1 10.0 13.4 Formula C2  9.214.6

The trapping behavior that was achieved was also good enough forflexographic printing process as presented in the following results:

Achieved Web Offset (min) Red: 99% 65% Green: 96% 75% Blue: 95% 70%

Based on the concept described in the present invention many formulavariations of the kind described here may be implemented by formulatorsskilled in the art. There are a large number of choices regardingnon-reactive solvents, solvent-soluble resins, monomers and oligomersthat would allow compliance with the claims of this invention. Also, theHansen Solubility Parameters for many other monomers and oligomers arenot currently known. Such data would help develop ink formulationswithin the scope of this invention without requiring numerous trials.

The invention claimed is:
 1. A flexographic printing apparatuscomprising: a feeding system which provides a flexographic ink,comprising a non-reactive polymer and a combination of materialsselected from the group consisting of monomers, oligomers, diluents,colorants, additives, and photo-initiators, wherein the ink in a liquidstate has a viscosity ranging from about 100 cps to about 4,000 cps, andthe ink in a gel state has a hardness measurable by ASTM D2240-05. 2.The apparatus according to claim 1, wherein the feeding system comprisesat least one heat source for the ink.
 3. The apparatus according toclaim 1, wherein the feeding system comprises at least one componentable to deliver shear force to the ink.
 4. The apparatus according toclaim 3, wherein the at least one component is selected from the groupconsisting of a stirrer, a mixer, an agitator, and a metering roll. 5.The apparatus according to claim 1, wherein the feeding system isautomatic.
 6. The apparatus according to claim 1, wherein the feedingsystem is manual.
 7. The apparatus according to claim 1, wherein theapparatus further comprises an ink tray.
 8. The apparatus according toclaim 7, wherein the feeding system supplies ink to the ink tray.
 9. Theapparatus according to claim 7, wherein the ink tray supplies the ink toa metering roll.
 10. The apparatus according to claim 7, wherein the inktray supplies the ink to an anilox roll.
 11. The apparatus according toclaim 9, wherein the metering roll transfers the ink to an anilox roll.12. The apparatus according to claim 1, further comprising a gelled inkreservoir.
 13. The apparatus according to claim 12, wherein thereservoir comprises a low speed metering roll and a medium speedmetering roll.
 14. The apparatus according to claim 13, wherein themetering rolls transfer the ink to the anilox roll.
 15. The apparatusaccording to claim 1, further comprising means for removing excess inkprior to application to an anilox roll.
 16. The apparatus according toclaim 15, wherein the excess ink is removed by a blade.
 17. Theapparatus according to claim 15, wherein the ink is transferred from theanilox roll to a plate cylinder.
 18. The apparatus according to claim17, wherein the ink is transferred from the plate cylinder to asubstrate.
 19. The apparatus according to claim 1, wherein the inktransitions from the gel state to the liquid state in the feedingsystem.
 20. The apparatus according to claim 12, wherein the inktransitions from the gel state to the liquid state in the reservoir. 21.The apparatus according to claim 1, wherein the ink transitions from thegel state to the liquid state prior to application to a substrate. 22.The apparatus according to claim 1, further comprising a contention can.23. The apparatus according to claim 1, further comprising a dryertunnel.
 24. The apparatus according to claim 1, further comprising oneor more inking stations and a drying system after each inking station.25. The apparatus according to claim 1, further comprising at least onechilling rod.
 26. The apparatus according to claim 1, further comprisingan electron beam device.
 27. The apparatus according to claim 1, furthercomprising an ultra-violet light device.
 28. The apparatus according toclaim 1, further comprising an ultra-violet light device and an electronbeam device.